机车轴承保持架注塑成型工艺及模具CAE技术研究
摘要
工程塑料以其独特的性能优势,在铁路运输的应用日趋广泛,以满足其“高速、重载、轻量化”的发展需求。目前,国内机车轴承塑料保持架研究是铁道部“十一五”发展规划需要攻克的一项重要技术,对其进行注塑模具设计及CAE研究,同时可以扩展到其它同类零部件的研究,具有很重要的实用意义。
本课题在分析了机车轴承塑料保持架的注塑成型过程各阶段的特点及主要工艺参数对注塑产品质量的影响的基础上,利用现代注射成形数值模拟软件和技术,采用理论设计和CAE设计同步进行的方式,系统研究了机车轴承塑料保持架注塑成形工艺、成形模具设计及成形过程中可能出现的各种缺陷及不足。
首先,塑件成形工艺分析:根据塑件的结构特点初步确定其注塑成型工艺及各工艺参数,以此作为有限元模拟时前处理过程中设计控制变量的主要参考依据,然后在有限元分析软件Mouldflow中进行数学建模、网格划分、材料选择、注塑机选择、成形过程预分析等,完成充型过程、浇注系统及冷却系统的有限元分析与模拟;
其次,最优成形工艺方案确定:改变各工艺参数以形成多种不同的成型方案,在对输出结果进行合理分析的基础上,如注射时间、压力、气穴、熔接线等,结合模具制造特点,确定出最优的注射成形工艺方案;
最后,以模拟分析得到的最优成形工艺方案为基础,对保持架注塑模具的关键零部件进行结构设计,包括分型面、型腔、浇注系统、脱模斜度、模架、导向定位机构、顶出机构及温度调节系统等,进而完成整套注塑模具设计,并阐明了该模具的工作原理。
Adjusting to the railage requirement of "high-speeded, heavily-loaded, light-quantified", the engineering plastics tends to be widely used increasingly by its superiority performance. Nowadays, the design of locomotive-bearing cage is an important technology which should be solved according to the Ministry of Railways' report on the outline of the Eleventh Five-Year Plan. Thus, the study of its injection mould designed by CAE is not only representative, but also can be referenced in other related fields.
Based on the characteristic of every step in injection molding and the influence of the primary process parameters on manufacture quality, we used by the injection molding numerical simulation software and technology, designed the mold alternately with theory and CAE. The paper also studied every possible deficiency in the locomotive-bearing cage process including injection molding process, the mold design, and forming process.
First of all, plastic parts processing analysis: elementary determined the injection molding process and the processing parameters according to the design feature of plastic parts. Further, use it as the prime basis to design control variable in FEA analysis fore treatment process. Do the approach, such as mathematics mold building, meshing, materials selecting, injection molding machine selecting, processing fore analyzing step by step in Moldflow, a FEA software to complete the FEA analysis and numerical simulation of overflowing impression process, runner system, cooling system.
Secondly, determined the optimal forming process scheme: change process parameters to form a variety of plastic forming scheme. Based on the analysis of output data gained by injection simulation, consisted of inject time, pressure and weld line, combining the manufacturing features of molding, optimum forming technology of the injection molding was obtained.
In the end, from the optimum forming technology resulted by numerical simulation, design of components and parts of bearing cage injection molding were completed. The parting surface, the mold cavity, the runner system, the rake of taking off from, the mold bases, orientation positioning mechanism, ejecting mechanism and temperature-conditioning system were successfully designed. After the whole design, principle of the injection mold was illustrated.
本课题在分析了机车轴承塑料保持架的注塑成型过程各阶段的特点及主要工艺参数对注塑产品质量的影响的基础上,利用现代注射成形数值模拟软件和技术,采用理论设计和CAE设计同步进行的方式,系统研究了机车轴承塑料保持架注塑成形工艺、成形模具设计及成形过程中可能出现的各种缺陷及不足。
首先,塑件成形工艺分析:根据塑件的结构特点初步确定其注塑成型工艺及各工艺参数,以此作为有限元模拟时前处理过程中设计控制变量的主要参考依据,然后在有限元分析软件Mouldflow中进行数学建模、网格划分、材料选择、注塑机选择、成形过程预分析等,完成充型过程、浇注系统及冷却系统的有限元分析与模拟;
其次,最优成形工艺方案确定:改变各工艺参数以形成多种不同的成型方案,在对输出结果进行合理分析的基础上,如注射时间、压力、气穴、熔接线等,结合模具制造特点,确定出最优的注射成形工艺方案;
最后,以模拟分析得到的最优成形工艺方案为基础,对保持架注塑模具的关键零部件进行结构设计,包括分型面、型腔、浇注系统、脱模斜度、模架、导向定位机构、顶出机构及温度调节系统等,进而完成整套注塑模具设计,并阐明了该模具的工作原理。
Adjusting to the railage requirement of "high-speeded, heavily-loaded, light-quantified", the engineering plastics tends to be widely used increasingly by its superiority performance. Nowadays, the design of locomotive-bearing cage is an important technology which should be solved according to the Ministry of Railways' report on the outline of the Eleventh Five-Year Plan. Thus, the study of its injection mould designed by CAE is not only representative, but also can be referenced in other related fields.
Based on the characteristic of every step in injection molding and the influence of the primary process parameters on manufacture quality, we used by the injection molding numerical simulation software and technology, designed the mold alternately with theory and CAE. The paper also studied every possible deficiency in the locomotive-bearing cage process including injection molding process, the mold design, and forming process.
First of all, plastic parts processing analysis: elementary determined the injection molding process and the processing parameters according to the design feature of plastic parts. Further, use it as the prime basis to design control variable in FEA analysis fore treatment process. Do the approach, such as mathematics mold building, meshing, materials selecting, injection molding machine selecting, processing fore analyzing step by step in Moldflow, a FEA software to complete the FEA analysis and numerical simulation of overflowing impression process, runner system, cooling system.
Secondly, determined the optimal forming process scheme: change process parameters to form a variety of plastic forming scheme. Based on the analysis of output data gained by injection simulation, consisted of inject time, pressure and weld line, combining the manufacturing features of molding, optimum forming technology of the injection molding was obtained.
In the end, from the optimum forming technology resulted by numerical simulation, design of components and parts of bearing cage injection molding were completed. The parting surface, the mold cavity, the runner system, the rake of taking off from, the mold bases, orientation positioning mechanism, ejecting mechanism and temperature-conditioning system were successfully designed. After the whole design, principle of the injection mold was illustrated.
引文
[1]徐金瑶等.CAD/CAE在产品开发及塑料注塑模具设计中的应用.机械研究与应用.2001,14(3).50-51.
[2]项辉宇等.注塑过程CAE及其对模具与工艺设计的作用.山东大学学报.2004,34(2).27-30.
[3]李海梅,申长雨.注塑中的CAB技术(Ⅱ):应用方法[J].工程塑料应用,2004,32(1):59-63.
[4]王真.国外铁道车辆用合成材料的应用现状及其发展趋势(下).国外机车车辆工艺.1995,2.1-9.
[5]王明玮等.浅谈新型塑料保持架轴承的性能.专业管理.45-46.
[6]永井,摄男等[日].高速高温轴承塑料保持架的研究.国外轴承技术.2007,2.19-24.
[7]刘亚盈,蔡根喜等.轴承工程塑料保持架的制造与应用[J].工程塑料应用,1994,22(1):4-40.
[8]Himasekhar K,Wang K.K.CAE of molding cooling in jnjection molding using a three dimensional numerical simulations[J].J of Engineering for Industry.1992,114.213-218.
[9]洪慎章.实用注塑成型及模具设计[M].北京:机械工业出版社,2004.
[10]朱传祥.汽车保险杠注射模设计与制造.模具工业.2002,8(258).33-36.
[11]叶久新,王群.塑料制品成型及模具设计[M].长沙:湖南科学技术出版社,2000.
[12]唐志玉.塑料挤塑模与注塑模优化设计[M].北京:机械工业出版社,2001.
[13]陈志刚.塑料模具设计[M].北京:机械工业出版社,2004.
[14]Himasekhar K.Current trends in CAE:simulation of latest innovation molding[J].Advances in Polymer Technology.1993,12(3).233-241.
[15]张鹏.注射模CAE技术与软件选用方法.模具制造.2003,3(20).13-15.
[16]余晓容.注塑模优化设计理论的研究与应用[博士论文].郑州大学.2004.72-97.
[17]徐小青.基于PRO/E和Moldflow的显示器外壳注射模具没计.塑料工业.2005,33(12).26-29.
[18]刘晨雨.Moldflow软件流动分析及应用[学位论文].长春理工大学.2006.2-31.
[19]单岩,王蓓.moldflow模具分析技术基础[M].北京:清华大学出版社,2005.
[20]王真.国外铁道车辆用合成材料的应用现状及其发展趋势(上).国外机车车辆工艺.1995,1.1-6.
[21]胡正华.汽车用塑料新材料发展概况.塑料.2003,32(6).67-73.
[22]杨浩强.实体轴承保持架超塑挤压数值模拟研究[学位论文].河南科技大学.2003.8-10.
[23]董汉杰,陈愚.准高速客车轴承保持架结构的选型与分析.铁道车辆.1998,36(10).32-33
[24]刘军.塑料保持架在我国铁路轴承上的应用前景.内燃机车.1995,4(254).29-30.
[25]宋燕星.汽车复杂零件注塑模具CAE设计[学位论文].哈尔滨理工大学.2005.
[26]潘安徽,刘凤山等.铁路货车用工程塑料保持架材料筛选与性能测试.中国铁道科学.2005,26(1).100-104.
[27]周天博.工程塑料保持架成型工艺的研究.渤海大学学报.2006,27(4).358-361.
[28]邢玉清编译.简明塑料大全[M].哈尔滨:哈尔滨工业大学出版社,1989.
[29]杰源.注塑机选择全攻略.http://info.china.alibaba.com/news/detail/v5-d5598749.Html
[30]刘艳玲.汽车后视镜注塑模CAD&CAE研究[学位论文].北京交通大学.2007.20-38.
[31]陈志刚.塑料模具设计[M].北京:机械工业出版社,2004.
[32]Douglas M.Bryce.Plastic Injection Molding:Manufacturing Process Fundamentals,Volume Ⅰ(96 Edition),2003.
[33]于同敏,路全胜,葛东东.影响注塑制品尺寸的因素及控制措施.塑料科技,1994,(3):21-22.
[34]申长雨等.注塑成型制品质量的控制[J].工程塑料应用.1997,27(8).33-37.
[35]刘法谦等.注射成型缺陷及解决方法[M].2002.
[36]杨安,陈绚.注射成型塑料制品的常见缺陷及解决办法.南昌高专学报.2003,3.83-85.
[37]奚东.注塑成型中制品的缺陷原因及其对策.塑料科技.2000,3.34-38.
[38]王永平.注塑模具设计经验点评[M].北京:机械工业出版社,1988.
[39]许树勤,王文平.模具设计制造[M].北京:北京大学出版社,2003.
[40]李奇,朱江峰,江莹玉.模具构造与制造[M].出版社,2001.
[41]宋明熹.汽车灯具关键件塑料化及注射模CAD[学位论文].吉林大学.2005.8-29.
[42]董斌斌,申长雨.薄壁件注射成型流动分析,塑料工业,2003,31(4).25-28.
[43]王志新,贺敏等.基于CAE技术对薄壁制件注射成型的分析研究.汽车工艺与材料,2003,4.28-30.
[44]高占华,曹巨江.基于Moldflow的塑料流动分析及应用.模具制造.2007,2.1-2.
[45]张晓陆.基于Moldflow软件的流动方案分析.模具工业.2006,32(6).1-4.
[46]J.Beaumont,R.Sherman Successful Injection Molding Process,Design & Simulation,2002
[47]黄汉勇.使用Moldflow的分析功能以得到满意的注射方案.机械开发.1996,1.26-28.
[48]罗宇玲.基于Moldflow软件的注塑产品熔接痕分析及优化设计.模具制造.2006,11.17-19.
[49]Himasekhar K,Wang K.K.CAE of molding cooling in injection molding using a three dimensional numerical simulations[J].J of Engineering for Industry.I992,114.213-218.
[50]Wang Huachang.Model-element Ananlytic Method for Plastic Forming of Material.Journal of Wuhan University of Technology—Mater.Sci.Ed.2003,18(1).44-46.
[51]汤宏群,苏广才.Moldflow在注射成型中的应用.广西大学学报.2003.
[52]张晓陆.基于Moldflow软件的流动方案分析.模具工业.2006,32(6).1-4.
[53]刘春太,陈静波等.塑料注射成型保压过程的数值模拟.应用力学学报.2002,19
[54]路春.注塑模成型过程的模拟及优化[学位论文].上海海事大学.2005.8-14.
[55]何小宁.保持架注射模设计.模具制造.2005,2.47-49.
[56]钟志雄.塑料注射成型技术[M].广州:广东科技出版社,1995.
[2]项辉宇等.注塑过程CAE及其对模具与工艺设计的作用.山东大学学报.2004,34(2).27-30.
[3]李海梅,申长雨.注塑中的CAB技术(Ⅱ):应用方法[J].工程塑料应用,2004,32(1):59-63.
[4]王真.国外铁道车辆用合成材料的应用现状及其发展趋势(下).国外机车车辆工艺.1995,2.1-9.
[5]王明玮等.浅谈新型塑料保持架轴承的性能.专业管理.45-46.
[6]永井,摄男等[日].高速高温轴承塑料保持架的研究.国外轴承技术.2007,2.19-24.
[7]刘亚盈,蔡根喜等.轴承工程塑料保持架的制造与应用[J].工程塑料应用,1994,22(1):4-40.
[8]Himasekhar K,Wang K.K.CAE of molding cooling in jnjection molding using a three dimensional numerical simulations[J].J of Engineering for Industry.1992,114.213-218.
[9]洪慎章.实用注塑成型及模具设计[M].北京:机械工业出版社,2004.
[10]朱传祥.汽车保险杠注射模设计与制造.模具工业.2002,8(258).33-36.
[11]叶久新,王群.塑料制品成型及模具设计[M].长沙:湖南科学技术出版社,2000.
[12]唐志玉.塑料挤塑模与注塑模优化设计[M].北京:机械工业出版社,2001.
[13]陈志刚.塑料模具设计[M].北京:机械工业出版社,2004.
[14]Himasekhar K.Current trends in CAE:simulation of latest innovation molding[J].Advances in Polymer Technology.1993,12(3).233-241.
[15]张鹏.注射模CAE技术与软件选用方法.模具制造.2003,3(20).13-15.
[16]余晓容.注塑模优化设计理论的研究与应用[博士论文].郑州大学.2004.72-97.
[17]徐小青.基于PRO/E和Moldflow的显示器外壳注射模具没计.塑料工业.2005,33(12).26-29.
[18]刘晨雨.Moldflow软件流动分析及应用[学位论文].长春理工大学.2006.2-31.
[19]单岩,王蓓.moldflow模具分析技术基础[M].北京:清华大学出版社,2005.
[20]王真.国外铁道车辆用合成材料的应用现状及其发展趋势(上).国外机车车辆工艺.1995,1.1-6.
[21]胡正华.汽车用塑料新材料发展概况.塑料.2003,32(6).67-73.
[22]杨浩强.实体轴承保持架超塑挤压数值模拟研究[学位论文].河南科技大学.2003.8-10.
[23]董汉杰,陈愚.准高速客车轴承保持架结构的选型与分析.铁道车辆.1998,36(10).32-33
[24]刘军.塑料保持架在我国铁路轴承上的应用前景.内燃机车.1995,4(254).29-30.
[25]宋燕星.汽车复杂零件注塑模具CAE设计[学位论文].哈尔滨理工大学.2005.
[26]潘安徽,刘凤山等.铁路货车用工程塑料保持架材料筛选与性能测试.中国铁道科学.2005,26(1).100-104.
[27]周天博.工程塑料保持架成型工艺的研究.渤海大学学报.2006,27(4).358-361.
[28]邢玉清编译.简明塑料大全[M].哈尔滨:哈尔滨工业大学出版社,1989.
[29]杰源.注塑机选择全攻略.http://info.china.alibaba.com/news/detail/v5-d5598749.Html
[30]刘艳玲.汽车后视镜注塑模CAD&CAE研究[学位论文].北京交通大学.2007.20-38.
[31]陈志刚.塑料模具设计[M].北京:机械工业出版社,2004.
[32]Douglas M.Bryce.Plastic Injection Molding:Manufacturing Process Fundamentals,Volume Ⅰ(96 Edition),2003.
[33]于同敏,路全胜,葛东东.影响注塑制品尺寸的因素及控制措施.塑料科技,1994,(3):21-22.
[34]申长雨等.注塑成型制品质量的控制[J].工程塑料应用.1997,27(8).33-37.
[35]刘法谦等.注射成型缺陷及解决方法[M].2002.
[36]杨安,陈绚.注射成型塑料制品的常见缺陷及解决办法.南昌高专学报.2003,3.83-85.
[37]奚东.注塑成型中制品的缺陷原因及其对策.塑料科技.2000,3.34-38.
[38]王永平.注塑模具设计经验点评[M].北京:机械工业出版社,1988.
[39]许树勤,王文平.模具设计制造[M].北京:北京大学出版社,2003.
[40]李奇,朱江峰,江莹玉.模具构造与制造[M].出版社,2001.
[41]宋明熹.汽车灯具关键件塑料化及注射模CAD[学位论文].吉林大学.2005.8-29.
[42]董斌斌,申长雨.薄壁件注射成型流动分析,塑料工业,2003,31(4).25-28.
[43]王志新,贺敏等.基于CAE技术对薄壁制件注射成型的分析研究.汽车工艺与材料,2003,4.28-30.
[44]高占华,曹巨江.基于Moldflow的塑料流动分析及应用.模具制造.2007,2.1-2.
[45]张晓陆.基于Moldflow软件的流动方案分析.模具工业.2006,32(6).1-4.
[46]J.Beaumont,R.Sherman Successful Injection Molding Process,Design & Simulation,2002
[47]黄汉勇.使用Moldflow的分析功能以得到满意的注射方案.机械开发.1996,1.26-28.
[48]罗宇玲.基于Moldflow软件的注塑产品熔接痕分析及优化设计.模具制造.2006,11.17-19.
[49]Himasekhar K,Wang K.K.CAE of molding cooling in injection molding using a three dimensional numerical simulations[J].J of Engineering for Industry.I992,114.213-218.
[50]Wang Huachang.Model-element Ananlytic Method for Plastic Forming of Material.Journal of Wuhan University of Technology—Mater.Sci.Ed.2003,18(1).44-46.
[51]汤宏群,苏广才.Moldflow在注射成型中的应用.广西大学学报.2003.
[52]张晓陆.基于Moldflow软件的流动方案分析.模具工业.2006,32(6).1-4.
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